ESS M&R 4


Schedule

14-16 October 2019 • The Westin Indianapolis • Indianapolis, IN, USA


 

Sunday, 13 October 2019

5 p.m.

Registration

Monday, 14 October 2019

7 a.m.

Breakfast

8 a.m.

Opening Remarks
Kyle Edwards, ArcelorMittal Dofasco G. P.

8:15 a.m.

Plenary Lecturer
Alan Knight, ArcelorMittal 

9 a.m.

Break

Track A1:

9:30 a.m.

Recent Sustainability Developments in the Iron and Steel Industry
Janice Bolen, Hatch
The iron and steel industry is one of the biggest global emitters of carbon dioxide. There are a number of recent developments that are aiming to reduce the environmental footprint of the steel industry. An overview of some of the recent innovations will be provided, including: reduction in blast furnace production and the trend toward electric arc furnace steelmaking with scrap or direct reduced iron; hydrogen use in direct reduced iron processes with hydrogen created via green electricity; electrolysis of iron ore to directly create steel via green electricity; European developments under the ULCOS program (Blast furnace top gas recycling, HISarna); and ethanol production from waste carbon monoxide gases.

10 a.m.

ECOSHAFT®: The Ultimate in Scrap Pre-Heating
Roland V. Mueller, Eco-e AG
A new two-chamber finger and pusher free shaft system with integrated post combustion allows the drying and pre-heating of scrap to greater levels including the complete incineration of PCDD/F.

11 a.m.

Water Treatment Sludge Beneficiation for the Recycling of Iron Content
Gary Amendola, Amendola Engineering Inc.

11:30 a.m.

State-of-the-Art Automation for Water Treatment Plants for the Iron and Steel Industry
Edgardo La Bruna, Janus Automation LLC
Water treatment plants are a necessary and vital part for the production of steel. Continuous operation is required to provide adequate water to the different processes with minimum environmental impact. Reliability is a key factor in a water treatment plant; a failure can affect multiple production lines. The electrical and automation systems are key components of the plant. This paper discusses key aspects of the design, implementation, factory acceptance test and successful commissioning of a state-of-the-art control system for a water treatment plant for the steel industry. Areas included are functional specification, system architecture, MCC and drives integration, HMI, FAT plan and SAT plan.

Track B1:

9:30 a.m.

Formulation of Microbial-Produced Bio-Surfactant and Its Application in Enhanced Oil Recovery
Adesina Fadairo, Covenant University
This presentation discusses the production of a microbial-produced bio-surfactant and its application in enhanced oil recovery. The bacteria Pseudomonas sp. was isolated from human urine and fed on neem seed bio-diesel-derived product as the major carbon source. The bio-surfactant produced from the fermentation process was used to prepare three solutions of bio-surfactants and its EOR applications evaluated. The optimum oil recovery performance based on the percentage of oil recovered for the bio-surfactant concentrations was observed to be between 1–2 % concentrations. Therefore, the eco-friendly bio-surfactant produced from neem seed oil using Pseudomonas sp. showed promising potential for enhanced oil recovery applications.

10 a.m.

Spilled Oil and Sustainability: Are We Using All-Natural Resources to Our Advantage?
Alexandra Brasher, Kengro Corp.
In a world embattled with rising climates and carbon emissions, sustainable materials are becoming increasingly important. Simple yet impactful solutions lie in how we are responding to hydrocarbon spills. Biodegradable, plant-based solutions exist to eradicate these spills; why aren't we using them?

11 a.m.

Don’t Get Steamed
Chad Frierson, ChemTreat
This presentation will give an overview of modern chemistry and treatment methods for protecting low-pressure steam generators. It will also look at items to consider for plant designers, operators and technical personnel who are ultimately responsible for reliable and safe operation of their plant.

11:30 a.m.

Hot and Cold on Ceramic Inserts for Radiant Tube Efficiency
Carl Nicolia, PSNERGY LLC
High-value retrofit solutions can deliver greater tons per MBTU in gas-fired radiant tube furnaces on the heating side, as well as enhanced cooling capabilities in air-over-tube cooling applications.

Track A2:

1:30 p.m.

Recycling of Discarded Lithium Ion Batteries for Recovery of Cobalt and Manganese Values 
Nikhil Dhawan, Indian Institute of Technology
Metals such as lithium, cobalt and manganese are key factors for their recycling. In this study, discarded mixed mobile batteries were discharged, dismantled and separated into cathode and anode sheets followed by crushing in an attritor. The cathode material contains LiCoO2 and LiMn2O4 around 63.5 and 36.5%, respectively, while graphite is present in the anode material. The cathode material was ball milled to homogenize and reduced using purified graphite in a muffle furnace at different residence times and dosages. A statistical design is employed for optimization of reduction parameters. The reduced mass was dissolved in distilled water and resulting leach residue was magnetically separated. The obtained magnetic fraction contains cobalt and manganese oxide whereas graphite and lithium carbonate were found in nonmagnetic fraction and dried solution. The final composition of the product obtained at optimum condition is approximately 80% Co and 10% Mn respectively.

2 p.m.

Selective Carbothermic Reduction and Smelting (SCRS) Process for Beneficiation of Low-Grade Iron-Manganese Mineral Deposits
Basak Anameric, Natural Resources Research Institute, University of Minnesota Duluth
Manganese is a critically important element used by both the steel and energy industries. This is due to its unique chemical, physical and alloying properties. There is no substitute for manganese in these major industries so 100% of the demand is met via imports, leaving the U.S. vulnerable to supply and demand pressures outside its control. The U.S. has manganese mineral deposits and the steel industry generates thousands of tons each year of waste oxides containing various metals that are currently landfilled. Therefore, NRRI is advancing a novel process called selective carbothermic reduction and smelting (SCRS) to show that SCRS can be used to efficiently beneficiate manganese and other minerals/metals such as iron, chromium, titanium, vanadium, aluminum and silica, from low-grade ores or steel industry waste oxides.

3 p.m.

Fly Ash Utilization in Indian Coal Mining Sector

3:30 p.m.

TBD

Track B2:

1:30 p.m.

Developing a Novel Chemical Additive for Gas Migration Control During Cementing High-Pressure High-Temperature Wells
Rachit Desai, Texas A&M University
Cementing high-pressure high-temperature (HP/HT) gas wells is a challenging and expensive job. Problems such as weighting material segregation, excessive fluid loss, and shortages of water available for cement hydration can produce high-porosity cement structures that are prone to progressive gas migration. This work developed an HP/HT cement slurry with high resistance to gas migration by optimizing a novel additive that replaces multiple common additives. Fluid loss among other properties was optimized through various iterations of additives combinations at different concentrations. The cement hydration was monitored using computed tomography (CT) scans. The new additive showed a 25% enhancement in the cement hydration capacity. These results came from the coating of the cement particles with a layer that is capable of attracting more water molecules, which prevent the quick free-water separation and provide for a better and faster hydration. The suggested chemistry can deliver superior cement properties for HP/HT wells.

2 p.m.

Development of High-Performance Water-Based Drilling Fluid Using Biodegradable Environmentally Friendly Additives to Regulate the Drilling Fluid Properties in Water-Based Fluid
Abo Taleb, Missouri University of Science and Technology
Waste materials are a rising global issue in today’s society and are abundant. Waste materials come in many types from food wastes to hazardous chemical waste. All these waste materials are not being disposed properly, and they can cause a severe drawback in terms of personal safety of the people and environment contamination. To minimize these risks, a new alternative should be investigated on how to properly dispose and handle these waste materials.

3 p.m.

Applications of Artificial Neural Networks in Petroleum Engineering, Parts I and II: Choosing the Best Lost Circulation Treatment Strategy for Natural and Induced Fracture Formation

3:30 p.m.

From Data Collection to Data Analysis: How to Successfully Extract Useful Information From Big Data in the Oil and Gas Industry

4:30 p.m.

Panel Discussion With All Monday Authors

5:30 p.m.

Reception

Tuesday, 15 October 

8:15 a.m.

Keynote Lecturer
Chris DeArmitt, Phantom Plastics

Track A3

9:30 a.m.

Achieving Optimal Energy Savings in Hot Strip Mills With Predictive Solutions
Yuka Osaka, TMEIC
It is effective for the variable speed control with inverter drives to be properly applied to pumps and fans in the steel industry to save energy. The authors have developed a predictive energy-saving solution combined with inverter drives in hot strip mills to achieve more saving effects than inverter application only. The solution utilizes the pre-set calculation results for hot strip products and real-time operation information to predict precisely the desired flow amount at the optimal timing. The results produced significant energy savings in several plants.

10 a.m.

Reducing GHG Emissions Using Advanced Combustion Techniques
Russ Chapman, Firebridge Inc.
State-of the-art regenerative burner technology can produce “flameless” combustion when applied to processes where furnace temperatures exceed the auto-ignition temperature of the fuel. Flameless combustion reactions virtually eliminate the peak combustion temperatures typical of focused ignition combustion reactions thereby creating a highly uniform heating source. The elimination of flame peak temperature zones improves greenhouse gas emissions by reducing thermal NOx production within the flame. The uniform temperature profile exhibited in flameless combustion creates improved heat transfer predictability and allows for improved product quality at higher throughput levels while also reducing furnace losses and stresses on furnace components associated with flame impingement. The application of regenerative flameless burner technology is explored through facts obtained in an example of a quench furnace producing steel-abrasive shot. 

11 a.m.

Strategic Planning Considerations for Energy Efficiency Upgrades of Fan Systems: Do You Go With Retrofit or New?
Vern Martin, FLOWCARE Engineering Inc.
Quite often, decisions concerning energy upgrade modifications are made on the simple basis of how much energy is reduced and what it costs to implement. Is that all there is to it? For many energy reduction targets, the decision-making process will need to address the issue of whether to retrofit the equipment that is already in place or completely replace it. There are many factors that influence how a retrofit versus new decision is made and these may range from the basic to the complex. This presentation will address some of the strategic planning considerations with a focus on fan systems and includes a discussion of the element of risk as it pertains to several important areas. The objective of this presentation will be to outline these considerations in a “rule of thumb” fashion for the benefit of those who may be working their way through this planning process.

11:30 a.m.

Contingency Planning for Disaster Scenarios: Electricity, Cooling and Air Considerations
Steven Birtch, Aggreko
Deployment of temporary utilities including micro-grids and right sized utilities address present-day demand, reduce fuel consumption, increase reliability and reduce operational costs. Depending on the situation, improvements from 5% to 15% can be achieved. Moreover, effective deployment of temporary utilities frees up capital for high return investments. Consideration for temporary utility solutions including microgrids allow producers to adopt best practices and make informed choices as they implement new strategies.

Track B3

9:30 a.m.

Sustainable UV Coatings for Pipe: Eliminating VOCs and HAPs and Improving ROI in the Coating Process
Michael Kelly, Allied PhotoChemical Inc.
In today’s manufacturing environment, it is critical to eliminate VOCs and HAPs in coating processes, while improving bottom-line return on investment. Implementing UV coatings technology can eliminate red rust and corrosion on oil country tubular goods (OCTG) and line pipe, improving customer engagement and increase overall business.

10 a.m.

Descriptive Data Analysis to Identify the Relationship Between the Effective Circulation Density and Flow Rate Based on Flow Regimes 

11 a.m.

Minimizing Lost Circulation Non-Productive Time Using Expected Monetary Value and Decision Tree Analysis
Husam Alkinani, Missouri University of Science and Technology
This is the first study that considers a detailed probability and cost to treat the lost circulation problem. Thousands of treatment scenarios for each type of losses are conducted, and the expected monetary values (EMVs) for all scenarios are calculated. For each type of loss, the lowest EMV treatment strategy that is practically applicable in the field and makes sense is selected to be used to treat the losses and minimize non-productive time (NPT) and cost. If the losses did not stop after utilizing the proposed treatment strategies, it is recommended to use a liner hanger to isolate the losses zone and then continue drilling. In addition, a formalized methodology for responding to losses in the Shuaiba formation is established and provided as means of assisting drilling personnel to work through the lost circulation problem in a systematic way.

11:30 a.m.

Characterization of Acid-Induced Asphaltene Sludge in Carbonate Acidizing
Nikoo Golshahi, Texas A&M University
Acid stimulation techniques are used to remove near well-bore formation damage by increasing the permeability of production zones. One of the main concerns during acid stimulation is asphaltene precipitation. In the presence of asphaltic crude oil, acidizing may result in sludge generation which can further damage the formation. How acid would change the asphaltene structure is still unknown.

Track A4

1:30 p.m.

Technical Feasibility Study of Sceneries for Geothermal Energy Generation From Petroleum Fields
Samuel Francisco Martinez Hernandez, Universidad Industrial de Santander
Three scenarios of geothermal energy generation in petroleum fields are analyzed and compared based on a multi-criteria analysis.

2 p.m.

On-Line Robotics: A Safer, More Eco-Friendly Cleaning Solution for Industrial Water Containment Systems
Grant Swoke, Scantron Robotics USA
By using on-line robotics, industrial water containment cleaning can be done with increased safety and ecological consideration, all while reducing the overall costs. Tanks remain full and operational, which eliminates draining and dumping of water. Material is removed and dewatered, creating dry waste, which is safer to dispose of. Putting robots, not people, into confined spaces for inspections and cleanings can reduce risks and liabilities. Environmental and employee safety is increased, all while tanks and basins remain operational, eliminating the costs of shutdowns for cleaning.

3 p.m.

Cogeneration: Bundling Solutions for a Single Efficient Package
Robert Wright, Burns & McDonnell
Cogeneration can provide a packaged solution for multiple problems at industrial facilities. Cogeneration can address issues including waste gas, emissions, aging infrastructure, increasing efficiency, steam reliability and offsetting energy costs. This paper and presentation will evaluate how to balance these various drivers into a single project.

3:30 p.m.

Carbon Dioxide and Hydrochloric Acid Influences on Asphaltene Stability: A Molecular Level Approach
Nikoo Golshahi, Texas A&M University
Acid stimulation techniques are used to remove near-wellbore formation damage by increasing the permeability of production zones. One of the main concerns during acid stimulation is asphaltene precipitation. In the presence of asphaltic crude oil acidizing may result in sludge generation that can further damage the formation. How acid would change the asphaltene structure is still unknown. This study examines the influence of hydrochloric acid on the physicochemical properties of asphaltene using several analytical techniques. Chemical structure of precipitated asphaltene in the presence and absence of acid were characterized and compared. These results were coupled with the results of stability measurement to identify the effects of structural alteration on asphaltene stability in the oil matrix.